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The present invention falls within the technical field of the containers for pourable foodstuff. In particular, the invention relates to a forming station for producing pourable foodstuff containers.

The containers for pourable foodstuff (fruit juices, milk, sauces of various type, etc.) are obtained starting from a continuous band of packaging material formed by a plurality of layers of different materials coupled one to another (generally paper, aluminium and heat-seal plastic material, such as for example polyethylene), that is processed in a dedicated automatic machine.

An automatic machine intended for making such containers comprises a feeding station, wherein a band of packaging material is fed, and in particular is unwound from a reel.

The machine can comprise, downstream of the feeding station, a creasing station, wherein crease lines are made on the band. By crease lines those lines are meant that are impressed on the material in order to allow achieving a container having predetermined shape (flat wall parallelepiped) at the end of the respective production. Alternatively, creases can be made on the band before it is fed to the machine.

The band is then sterilized, for example by passing the same in a tank containing hydrogen peroxide, and then closed at a welding station of the machine, in such a way to form a tube open at an end. The open tube reaches the filling station where it is filled with the foodstuff.

In order to obtain flat wall parallelepiped containers with a predetermined foodstuff amount in their inside, the tube is carried to a forming station, where the container volume and shape are defined, before being subjected to the final welding.

In particular, the forming station comprises two forming plates, facing one another and movable in order to move closer to each other, the tube of packaging material being conveyed therebetween.

Each forming plate comprises a flat abutment wall, for abutting a corresponding tube portion that will constitute the container. Thereby, the flat abutment walls contribute to define the flat wall parallelepiped shape of the container and, at the same time, physically limit the volume of the tube (thus of the container) once filled, before the final welding.

Downstream or at the forming station cutting means are provided for separating the filled and closed containers.

The shape of the containers exiting from the forming station is optimized in a dedicated station.

In detail, at this dedicated station, the containers are arranged in corresponding "drawers" or "baskets" keeping their shape; at the same time, finishing operations made on the containers can be provided. For example some parts of the containers, such as the corners (i.e. the so-called "ears") or other edges previously welded that otherwise would protrude with respect to the container walls, are expected to be folded and welded on the container walls. Baskets containing the containers are conveyed at suitable stations where the afore said operations are carried out.

However, there is the need of making containers with shape differing from the flat wall parallelepiped one.

In fact, the afore said shape of the containers obtained with known machines firstly results in practical drawbacks: such as a not optimal container grip (low ergonomics) mostly when they are placed side by side, for example on a shelf, or close to a wall. In addition, when two or more containers are placed side by side one another, the reduced air circulation among the same can cause condensation forming, mostly under humid environmental conditions.

The forming stations being in known machines, such as the afore described one, do not allow obtaining containers having shape different from the flat wall parallelepiped one.

Object of the present invention is to overcome the afore described drawback.

Such an object is achieved by a forming station for producing pourable foodstuff containers according to the attached claims.

Advantageously, the forming station according to the invention allows making pourable foodstuff containers having a shape different from the flat wall parallelepiped shape of known art containers. This way, therefore, pourable foodstuff containers can be made specially ergonomic, i.e. easy to be gripped also in case they are placed side by side or close to a wall.

Furthermore, pourable foodstuff containers can be made by the invention that prevent condensation to be formed among the same, if they are placed for example side by side one to another.

Further advantages of the invention will be apparent in the following discussion, by the aid of the accompanying figures, in which:

figure 1 shows a perspective view of a forming station for producing pourable foodstuff containers according to the present invention, wherein some parts have been removed to better highlight others;

figure 2 shows a partial view of the section A-A of figure 1 ;

figure 3 shows a side view of the forming station of figure 1 ;

figure 4 is a perspective view of a detail of a forming station of figure 1 ; figure 5 shows a perspective view of a forming station according to the present invention, wherein some parts have been removed to better highlight others; figures 5A, 5B, 5C show as many partial, side views of the forming station of figure 5, in different operative conditions;

figures 6 and 6A show a perspective view and a side view, respectively, of conveying and definition units being part of a machine for producing pourable foodstuff containers according to the present invention;

figure 7 shows a perspective view of the conveying and definition unit of figure 6, in a first operative condition;

figure 7A shows a container arranged in the conveying and definition unit being part of the machine according to the invention, in the operative condition of figure 7, wherein some parts have been removed to better highlight others;

figures 8 and 8A are similar to figures 7 and 7A respectively, in a different operative condition;

figure 9 shows a container placed in the conveying and definition unit, in an operative condition different from the afore described ones;

- figure 10 shows a container that can be obtained by the invention.

In reference to the accompanying figures 1-5C, a forming station for producing containers C for pourable foodstuff starting from a tube T of packaging material according to the present invention, has been denoted with the reference 1. The containers C for pourable foodstuff (fruit juices, milk, sauces of various type, etc.) are obtained starting from a continuous band of packaging material (not shown), consisting of a plurality of layers of different materials coupled one to another (generally paper, aluminium and heat-seal plastic material, such as for example polyethylene), that is closed in order to form a tube T.

Generally, such containers C are defined by an upper wall Wl and a lower wall W2 opposed each other, by a front wall W3 and a rear wall W4 opposed each other, and by two side walls W5, W6 (see for example figure 10).

The forming station 1 according to the invention comprises: a first forming plate 2 and a second forming plate 3 opposed each other and movable along an abutment direction R and prearranged for receiving therebetween a portion of the tube T intended for originating a pourable foodstuff container C (see in particular figures 1 - 3).

Each forming plate 2, 3 comprises an abutment surface 20, 30, to each abut the portion of tube T filled with the pourable foodstuff.

In particular, the abutment surface 20 of the first forming plate 2 comprises a first portion 21 and a second portion 22 both shaped in such a way that the first portion 21 protrudes with respect to the second portion 22, and that the second portion 22 curves inward with respect to the first portion 21 , according to a transverse direction with respect to the lying plane P of the abutment surface 20 of the first forming plate 2 (the lying plane P has been partially shown in figure 4).

In other words, the first portion 21 of the abutment surface 20 of the first forming plate 2 protrudes towards the abutment surface 30 of the second forming plate 3, i.e. towards the portion of the tube T, once interposed between the first forming plate 2 and the second forming plate 3.

As known, in general, the first forming plate 2 and the second forming plate 3 abut (by the respective abutment surfaces 20, 30) the portion of the tube T being filled and, in particular, each abut a portion of the tube T intended for originating a wall of the container C. The first forming plate 2 and the second forming plate 3 constitute, therefore, also a physical limit to the volume of the container C.

Advantageously, by the invention, during the formation of the container C, the first portion 21 and the second portion 22 of the abutment surface 20 of the first forming plate 2 impress a corresponding shape (that will be optimized later, as it will be evident in the following text) to the walls of the container C. In other words, the container C that will be formed will not have parallelepiped shape with flat surfaces as in the known art (wherein the forming devices had flat abutment surfaces), but will have instead at least one wall with a protrusion and a recess. A non-limiting example of a container C that can be obtained by the forming station 1 according to the invention is shown in figure 10, wherein the front wall W3 has two protrusions. Clearly, the tube T from which the container C is originated will have suitable crease lines S (i.e. lines impressed on the packaging material, see figure 10) adapted to aid the operation of the first forming plate 2.

Preferably, only one of the first forming plate 2 and the second forming plate 3 can be translationally moved along the abutment direction R.

Alternatively, both the forming plates 2, 3 can be translationally moved in order to move closer and away to/from each other, along the abutment direction R.

The first portion 21 can take up an area of the abutment surface 20 having extent varying according to needs, i.e. according to the shape of the container C to be obtained. In the same way, the first portion 21 can be more extended, less extended, or have equal extent with respect to the second portion 22 of the abutment surface

20.

In the example shown in figure 4, the first portion 21 extends from a first edge Bl of the abutment surface 20 to a second edge B2 of the abutment surface 20. Alternatively, according to an example not shown, the first portion 21 can have an extent lower than that of the previous example, i.e. can extend for example from the first edge Bl of the abutment surface 20 to the center line of the abutment surface 20. According to a preferred embodiment of the invention, the first portion 21 has an arched profile, convex with respect to the lying plane P and to the second portion 22 (see figure 4). Such a specification gives the so-obtained container C an improved appearance with respect to known type containers. In fact, by considering for example figure 10, the front wall W3 of the container C is shaped in such a way to have concave and convex portions following one another (with respect to the longitudinal development axis Y of the container).

Alternatively, the first portion 21 and the second portion 22 of the abutment surface 20 of the first forming plate 2 each has a profile defined by broken lines (not shown variation).

According to the preferred embodiment, the abutment surface 20 of the first forming plate 2 further comprises a third portion 23 shaped in such a way to protrude with respect to the second portion 22, according to the transverse direction with respect to the lying plane P of the abutment surface 20 (see figure 4). In detail, the second portion 22 is interposed between the first portion 21 and the third portion 23, along a development axis L of the abutment surface 20 (the axis L is shown in figure 4). With such an embodiment, for example, a container C such as that of figure 10 can be obtained.

Clearly, more than two portions can be provided as protruding with respect to said lying plane P.

As known, the portion of tube T intended for originating a container C for pourable foodstuff comprises at least one end zone E, at which the tube T is welded.

The forming station 1 can further comprise supporting means 5, 50 arranged under the first forming plate 2 and the second forming plate 3, in such a way that said end zone E rests on the supporting means and is supported during the operation of the first forming plate 2 and the second forming plate 3 on the portion of tube T.

For example, in the embodiment shown in figures 1-3, the supporting means 5, 50 comprise two supporting elements 5, 50 movable in order to move closer to each other along a direction parallel to the abutment direction R (see figures 1-3). The supporting elements 5, 50 receive the end zone E, which rests on them, of the container C under forming in the forming station 1 and contribute in this way to define the final shape of the container C, thus ensuring a better control to operations of the first forming plate 2 and the second forming plate 3. In the embodiment shown in figures 1-3, the supporting elements 5, 50 are shaped in such a way to define a V profile when they are arranged at a minimum mutual distance. For example, the abutment surface 30 of the second forming plate 3 can be flat.

Alternatively, according to a variation not shown, the abutment surface of the second forming plate can have the same characteristics described for the abutment surface of the first forming plate (i.e. can have at least one protrusion and at least one recess). In other words, also the abutment surface of the second forming plate can comprise a first portion and a second portion, both shaped in such a way that the first portion protrudes with respect to the second portion and the second portion curves inward with respect to the first portion, according to a transverse direction with respect to the lying plane of the abutment surface of the second forming plate. In this case, the profile of the abutment surface of the second forming plate is not necessarily the same as the profile of the abutment surface of the first forming plate.

According to an embodiment of the invention, the forming station 1 further comprises a first folding group 6 and a second folding group 7, which are bilaterally arranged with respect to the first forming plate 2 and the second forming plate 3 (i.e. arranged at the opposite sides of the first forming plate 2 and the second forming plate 3). The first folding group 6 and the second folding group 7 are opposed each other along a folding direction F transversal to the abutment direction R (refer to figures 5, 5A, 5B, 5C).

Each folding group 6, 7 comprises a folding element 60, 70 provided with a folding side 61 , 71 oblique with respect to the folding direction F, contacting a wall of the container C under forming (i.e. a part of the tube T) and pressing against the same during the respective movement along the folding direction F. In reference to the example of figures 5, 5A, 5B, 5C each folding element 60, 70 causes, thanks to the corresponding folding side 61 , 71 , the formation of those that will be the upper wall Wl and the lower wall W2 of the container C once it has been formed.

In particular, in figures 5, 5 A, 5B, 5C, the folding side 61, 71 of each folding element has a profile identified by two segments converging one to another, each one oblique with respect to the folding direction F.

In the embodiment of figure 10, the upper wall Wl and the lower wall W2 of the container C obtained by the invention (and thus with the first folding group 6 and the second folding group 7) have trapezoidal shape. Figures 5A, 5B, 5C show, in detail, three operative consecutive steps of the operation of the first folding group 6 and the second folding group 7 on the portion of tube T that will originate a container C for pourable foodstuff.

For example, each folding group 6, 7 comprises a kinematic mechanism 9, 90 for moving the corresponding folding element 60, 70.

Each kinematic mechanism 9, 90 can comprise a support 9 connected to the corresponding folding element 60, 70, a frame (not shown) and at least one connection element 90 hinged to the frame and the support 9. In this way, advantageously, the movement of the folding elements 60, 70 is particularly controlled and effective.

In reference to figures 5, 5A, 5B, 5C, each kinematic mechanism 9, 90 comprises four connection elements 90 parallel one to another.

Preferably, each kinematic mechanism 9, 90 comprises an articulated quadrilateral; in particular, according to the preferred embodiment shown, each kinematic mechanism comprises 9, 90 an articulated parallelogram.

The invention further relates to a machine (only partially shown) for producing pourable foodstuff containers C, comprising a forming station 1 according to one of the afore described embodiments; welding means (not shown) to weld the formed and filled tube T in corresponding closed and filled wrappers; cutting means (not shown), for separating the wrappers and locate the containers C filled and formed in the forming station 1.

The machine further comprises at least one conveying and definition unit 10 placed downstream of the cutting means and movable along a conveying path (see figures 6- 9). The conveying and definition unit 10 comprises a containing and definition frame 1 1, 12, 13 comprising in its turn at least one first containment wall 1 1 and one second containment wall 12 opposed each other, in order to receive between them a container C filled and formed in the forming station 1. Each containment wall 1 1 , 12 comprises a containment surface 1 10, 120 in order to abut a corresponding wall (for example the front wall W3 and the rear wall W4) of the container C.

The containing and definition frame 1 1 , 12, 13 can further comprise a bottom 13 arranged between the first containment wall 1 1 and the second containment wall 12, the bottom receiving a container wall resting thereon (for example a side wall W5, W6).

In particular, the containment surface 1 10 of the first containment wall 1 1 comprises a first portion 1 1 1 and a second portion 1 12 both shaped in such a way that the first portion 1 1 1 protrudes with respect to the second portion 1 12, and that the second portion 1 12 curves inward with respect to the first portion 1 1 1, according to a transverse direction (preferably perpendicular) with respect to the lying plane G of the containment surface 1 10 of the first containment wall 1 1 (see figures 6, 6A). The lying plane G has only been shown in figure 6 for the sake of clarity.

According to the preferred embodiment, the first portion 1 1 1 and the second portion 1 12 of the first containment wall 1 10 have the same profile as the first portion 21 and the second portion 22 of the abutment surface 20 of the first forming plate 2.

In this way, advantageously, the conveying and definition unit 10 optimizes the final shape of the container C, as it will be more evident in the following of the present discussion.

According to an alternative, the profile of the first portion and second portion of the first containment wall could not be the same as the profile of the first portion and second portion of the abutment surface of the first forming plate.

According to the preferred embodiment shown (similarly to what mentioned for the first forming plate 2), the containment surface 1 10 of the first containment wall 11 can further comprise a third portion 1 13 shaped in such a way to protrude with respect to the second portion 1 12, according to a transverse direction (preferably perpendicular) with respect to the lying plane G of the containment surface 1 10 (see figures 6, 7, 8). In detail, the second portion 1 12 is interposed between the first portion 1 1 1 and the third portion 1 13, along a development axis O of the abutment surface 1 10 (the development axis O is shown only in figure 6 as an example).

With such an embodiment, for example, a container C such as that of figure 10 can be obtained.

The container C, exiting from the forming station, can be conveyed in horizontal position with respect to the floor plane (i.e. resting on the respective rear wall W4) or in vertical position with respect to the floor plane (i.e. resting on the respective upper wall Wl or the respective lower wall W2).

Along the afore said conveying path one or more stations are provided, for example, being part of the machine according to the invention, at which stations the container C undergoes final operations (see in particular figures 7, 7A, 8, 8A, 9).

For example, in figures 7 and 7A, the folding of the corners Z (i. e. the so called "ears") is shown against a corresponding fixed support N. The fixed supports N are bilaterally arranged with respect to the containing and definition frame 1 1 1 , 1 12, 1 13. In detail, for the sake of further clarity, the container C has not been depicted in figure 7, while the containing and definition frame 1 1 1, 1 12, 1 13 has not been depicted in figure 7A.

In figures 8 and 8A, instead, the conveying and definition unit 10 is arranged at squaring elements B (bushes) able to square the upper wall Wl and the lower wall W2 of the container C. The squaring elements B are bilaterally arranged (i.e. at the opposite sides) of the containing and definition frame 1 1 1 , 1 12, 1 13 (therefore of the container C). In detail, for further clarity, in figure 8 the container C has not been depicted, while in figure 8A the containing and definition frame 1 1 1 , 1 12, 1 13 has not been depicted.

Figure 9 shows, instead, a container C arranged in the conveying and definition unit 10 (the containing and definition frame 1 1 1 , 1 12, 1 13 has not been depicted) where the corners Z of the container C itself are led thanks to fixed guides M, to the respective final configuration, i.e. they are pressed against walls of the container (for example the lower wall W2 and side walls W5, W6). The fixed guides M are part of the machine according to the invention.

Therefore, the conformation of the conveying and definition unit 10 advantageously allows retaining and optimizing the shape of the container C: otherwise, the shape of the container C could be deformed by the operations occurring on the same.

The forming station 1 and the machine according to the invention allow obtaining containers C with at least one wall having protrusions and recesses, thus having a different shape different with respect to the parallelepiped containers with flat walls of known art. The machine according to the invention can further comprise, upstream of the forming station 1 and the conveying and definition unit 10, a feeding station, wherein a band of packaging material is fed and in particular is unwound from a reel (stations not shown).

In addition the machine can comprise, downstream of the feeding station, a creasing station, wherein crease lines are made on the band, and a band sterilizing station (in which the band is sterilized, for example, by passing the same in a tank containing hydrogen peroxide) (stations not shown).

The machine can further comprise a filling station where the tube (welded by welding means, also being part of the machine) is filled with the foodstuff.